Process of forming steel ingots in sectional molds



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J. B. DA. BOULTON. PROUBSS 0F FORMING STEEL INGOTS IN SEG-TIONAL MOLDS.

Patented Nov. 4,

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J. B. DA. BOULTON.

PROCESS OF FORMING STEEL INGOTS IN SECTIONAL MOLDS. No. 440,097. Patented Nov. 4, 1890.

NITED STATES PATENT FFI'CE.

JAMES B. DARGY BOULTON, OF JERSEY CITY, NEW JERSEY, ASSIGNOR TO THE SOLID IN GOT COMPANY, OF NEW JERSEY.

PROCESS OF FORMlNG STEEL INGOTS IN SECTIONAL MOLDS.

SPECIFICATION forming part of Letters Patent No. 440,097, dated November 4, 1890.

Application filed March 25, 1887. Serial No. 232,362. (No model.)

To all whom it may concern:

Be it known that 1, JAMES B. DARoY BOUL- TON, a subject of the Queen of Great Britain, residing at Jersey City, Hudson county, New Jersey, have invented certain new and useful Improvements in the Process of Forming Steel Ingots in Sectional Molds, fully described and represented in the following specification and the accompanying drawings, forming a part of the same.

My invention relates especially to the production of cast-steel ingots; and the object of the invention is to form a steel casting which may be sound and free from defects by reason of the perfect feeding of the fluid metal during the shrinkage in cooling, and which may be conveniently separated into a series of ingots of the desired size.

My process is adapted to produce a coldshut around the periphery of the casting at regular intervals, which predisposes the casting to rupture at such points; and my invention also provides for rupturing the casting at such points before its removal from the molds.

The apparatus shown herein is claimed by me in another patent-application, Serial No. 232,361, filed March 25, 1887.

To distinguish more clearly my invention from others in the same class, I will refer to a number of devices in the use of which various processes somewhat analogous to mine are practiced.

I am aware that an ingot-bar has been formed by pouring the metal within a mold having a falling bottom, and that it is common to super-pose a series of molds upon one another with perforated dividing-plates of metal or refractory material to permit the flow of the metal from one of such molds to another, as in British Patent No. 4,425 of 1876. I am also aware that in British Patent No. 3,379 of 1878 a single long mold is described, with provision for dropping notched partitions at various points within the same to divide the contents while fluid, and that a series of molds has been superposed with intervening plates and with a central core having ducts leading into each of such molds for the production of tire-castings, as in British Patent No. 2,886 of 1865, and in British Patent No. 1,221 of 1873, which also shows a series of molds connected with a crucible to permit the passage of the metal from the crucible to the molds. I am also aware of United 5 5 States Patent No. 342,920, issued June 1, 1886, for an improved ingot-mold,showing a series of mold-sections which are divided longitudinally and secured to traveling carriers, and of the provisional British Patent No. 2,996, issued December 7, 1860, to J. G.Haddan, which contains the mere suggestion that a mold may be made in pieces fitted upon one another to be built up in successive stages during casting, so as to pour the molten metal a short distance only.

As one object of my invention is to produce a bar which may be easily divided, my process differs from the use of any apparatus shown or described in the above-named references in the removal successively of the lower sections of the series with their contained ingots, and the addition successively of mold-sections to the top of the series, and in the filling successively of each upper section when placed in the series, with a distinct separate charge of fluid metal. By such method of filling the sections any want of continuity in the continuous casting, which is certain to result from my method of pour- 8o ing, will manifest itself at the junctionof the mold-sections and predispose the casting to rupture at such point into separate ingots,--asdesired.

I am aware that it has been proposed to form a continuous ingot bar by the pouring of the metal into a single mold and moving the metal downward within the moldafter each charge to make room for a subsequent charge; and my invention differs from such 0 a process in employing a series of separate mold-sections, which are moved downward with their separate charges of metal to avoid the shifting of the metal within the mold.

In forming an ingot-bar by shifting the metal within the mold it becomes necessary to delay pouring a subsequent charge until the previous one has become loosened in the mold by shrinkage sufficiently to move downward without the rupture of its particles. As rco an expansion results from the crystallization of the metal when it passes from a fluid to a semi-solid state, it is obvious that considerable delay is required after pouring each charge to efiect such shrinkage of its bulk as will permit it to be moved downward without rupture, and to facilitate such cooling it is necessary in practicing said invention to apply a water-jacket to the mold, which by chilling the metal in a rapid manner prevents the disengagement of the gases to the fullest extent desired. The movement of the metal downward within the mold also requires the use of some force applied to the cold part of the ingot, which, if the strain be applied hastily, is liable to rupture the ingot-bar or to lessen the contact and cohesion of its particles, so as to form a loose and porous prod not.

By the use of my invention to form an 1ngot-bar there is no necessity to hasten the cooling of the metal, as heavy mold-sections adapted to conduct the heat away at a moderate rate may be used instead of a waterjacket, which is liable to chill the exterior of the ingot long before the interior is cooled, and thus prevent the formation of a homogeneous ingot.

By the use of my sectional molds sustained movably within the holder and by pouring the separate charges of metal within said mold-sections as rapidly as they can be filled and moved downward I am enabled to effect a more perfect union of the central portion of the metal in the diiferent charges, and I am enabled more perfectly to feed the shrinkage of the lower molds from the upper one containing the hottest metal, and may thus produce an ingot-bar with much greater rapidity and with better results than by the methods previously used.

The annexed drawings represent one form of apparatus for practicing my invention, being the same with that shown in my patentapplication, Serial N 0. 232,361, Figure 1 being an edge View of the apparatus, and Fig. 2 a section of the same on line a; a: in Fig. 1. Fig. 3 is a view of the top apparatus, and Fig. 4 a view of thelower end of the same.

The apparatus is shown mounted upon two cross-bars K, the ends of which are shown sus tained upon walls K, between which a portion of the apparatus hangs. Such bars K are secured by rivets r to cylinders L. The beam A is secured to one of the bars K, the beam A being free tomove toward and away from the beam A. The mold-sections are sustained during the pouring operation in a spring-holder consisting in two beams A A, pressed toward one another by springs B, and the mold-sections are guided in their downward movement between the beams by flanges 0 upon. the edges of the beams. b is a moldseetion adjusted within the holder with its mouthjust below the top of the latter ready for filling. b is a section immediately beneaththe same and already filled with fluid rods 2'.

section beneath clamped upon opposite sides of the beams by bolts m. Pistons f f are shown within the cylinders carrying movable portions 6, the two portions forming a pocket to receive the lower mold section b when forced entirely from the bottom of the holder and to shift the ingot sidewise to fracture the metal therein from that in the section b sustained by the guide. A spring-presser e is located in the side of the pocket and operates by its friction to support the weight of the mold-section held therein when the lower mold-section and its contained ingot are moved laterally by the poekete. Thestrain thrown upon the mold-section 12 is sustained by abutments which are formed as two keys A and A ,inserted through an aperture in the upper side of the cylinder f adjacent to the ends of the beams A A.

The pressure of the beams A A serves to support the weight of the mold-sections within the holder, and in order to move the moldsections downward after each is filled with a separate charge of fluid metal a pusher h is provided and actuated by hydraulic piston- The pusher embraces the holder loosely, and is provided with pawls g, which engage the the mold-sections by pressing into notches is, formed in their opposite sides. An empty mold-section b is sustained above the top of the holder by the clamp s at a sufficient distance to admit the fluid metal to the section b.

The operation of the apparatus is as follows: The mold-section in the top of the holder is filled'withfluid metal and a suitable packing-washer c is laid upon the top end of the section. The empty mold-section b is placed upon such packing. The carrier and pawls are now raised to the top of their stroke, thus releasing the arm 3 from contact with the notches, and the pawls engage with the notches of the superposed section, so that upon the downward stroke the pusher and pawl will press such mold-section downward until its top is slightly below the top of the holder, and at the same time forcing all the sections below it downward a similar distance. The empty section then occupies the place of the previously-filled sections, and may be immediately filled with the fluid metal before any material diminution of temperature occurs in the metal of the section previouslyfilled. The metal in the two sections thus becomes firmly united, and any shrinkage within the section first filled is promptly supplied before the surface of the temperature within the top section.

metal is chilled by the fresh metal at-a high While the empty section is being filled the lowest section b may be shifted laterally by the pis- I tons f f and the separation of the bar effected between the ends of the adjacent sections 12 6 as fully set forth in my patent-application, Serial No. 232,361. After such separation of the metal the mold-section b is held directly beneath the section b so that the succeeding movement of the sections within the holder may force the section b from the pocket 6 with its contained ingot. The operation of thus filling the mold-sections with separate charges of fluid metal and lowering them successively within the holder may be con-tinned indefinitely with the result of forming a series of connected ingots adapted to be separated from one another before their removal from the apparatus or from the mold sections in which they were cast. If desired, any suitable cooling means may be applied to the lower mold-sections of the series to lit the cast metal for removal from the same.

As stated above, mold-sections with metal walls more or less thick in proportion to the internal bore may be used to cool their contents at the desired rate; but in any case the upper mold-section may be moved downward as soon as it is filled, and the entire process may therefore be conducted so rapidly that thecontents of the upper sections within the holder are cooled very little before the metal in them is united, thus securing the complete feeding to the shrinking metal of the hot metal last supplied and the formation of solid castings, as desired.

From the above description my invention will readily be distinguished from those intended to form a continuous homogeneous ingot-barz'. 6., a bar with no joint, break, or cold-shut in it causinghomogeneousportions of it to be readily separable into homogeneous ingots. In inventions which effect such an ingot-bar there cannot be successive pourings of the fluid metal in separate charges, for the reason that when separate charges are poured one upon another the surface of the metal is certain to chill in some degree where in contact at its edges with the surrounding mold in the interval of time between the pourings of the successive charges, and to thus exhibit a cold-shut or defect in continuity at the joint of the separate charges.

My invention is designed particularly to take advantage of such defects in continuity which result from the pouring of separate charges upon one another, and the process is essentially one for forming a continuous casting which is peculiarly adapted for separation into separate ingots. This continuous casting would not of course be homogeneous throughout its length by reason of the defects formed at intervals by the cold-shuts, and which defects could never be eradicated by hammering or rolling. The separate sections between the cold-shuts would, however,

be homogeneous or of even texture adapted for the manufacture of sound articles of any desired form.

By my invention I am able to form a series of connected ingots which are free from piping and blow-holes by reason of the perfect feeding to the shrinking metal of the hot metal in the subsequent charge and to effect the separation of the casting into distinctingots precisely at the joint of the several moldsections in which the casting is formed by reason of the cold-shut formed at the surface of the metal on the top of each charge.

The mold-sections I employ are readily distinguishable from those which have been heretofore superposed in a definite number and secured together to be simultaneously filled, as my mold-sections are movable and are only superposed one at a time and are filled with separate charges of fluid metal, and the operation may be continued indefinitely, which is not possible with any of the constructions shown in the various patents referred to by me above.

I hereby disclaim the inventions described in the several patents referred to above, and especially the specific process which consists in the pouringof separate charges successively within the same mold, the metal previously poured being displaced within the mold to make room for each subsequent charge. I have stated above the objections to such method of forming an ingot and the delay necessitated by waiting for each charge to cool sufficiently to bear shifting downward within the mold and the danger of cracking or rupturing the casting if such movement within the mold be effected before a sufficient hardening of the metal has taken place.

In my invention the successive charges are not poured within the same mold, but in separate mold-sections; and, furthermore, the metal is not under any circumstances shifted or moved within the mold or subjected to any external force, as is required for moving the metal within the mold, and which is liable to injure the strength or continuity of the castmg. l I

I am aware of United States Patent No. 342,920, dated June 1, 1886, which shows two endless-chain carriers carrying sectional parts of a longitudinally-divided mold and operated by placing it in an inclined position and pouring the metal in a continuous stream into the mold which is formed by the adjacent parts; This invetion differs from mine, in that the molds are not arranged in a Vertical posit-ion and placed with their open ends one upon another and in not supplying the mold with a series of separate charges, which, while it produces in my invention an advantageous lack of continuity where the cold-shut exists at the junction of the separate molds, would produce a most injurious oblique seam in the surface of the continuous ingot produced by the apparatus of the said patent. I therefore disclaim the process described in the said patent and any other for forming a continuous homogeneous ingot.

In the use of those features of my invention heretofore described I employ, as will have been observed, a process consisting in casting one portion and while that portion is partially chilled or hardened in its outer parts casting another portion onto the first portion. Thus, broadly considered, I regard this lastdescribed process as of my invention, although I do not wish to lay claim specifically to that particular modification of or improvement upon it, which I have heretofore disclaimed, and which consists in forming a continuous ingot-bar by the pouring of the metal into a single mold and moving the metal downward within the mold after each charge to make room for a subsequent charge.

Having thus set forth my invention, what I claim herein is 1. The process of forming a cast steel or metal ingot in separable sections partially divided by a cold-shut, which consists, first, in pouring the metal into one mold-section; secondly, superposing another and bottomless mold-section upon the top of such filled moldsection; thirdly, pouring a separate charge of metalin such second mold-section, and continuing the process of applying separate moldsections and supplying them with separate charges of fluid metal so long as desired, substantially as herein set forth.

2. The process of forming a continuous steel casting in separable sections partially divided by a cold-shut, which consists, first, in filling a vertical moldsection with a separate charge of fluid metal; secondly, supporting on the filled mold-section a second and bottomless mold-section; thirdly, furnishing the second or superposed mold-section with a separate charge of metal, whereby a coldshut is formed at the junction of the sections; fourthly, separating the ingot of one moldsection from the ingots in the other remaining mold-sections, and, fifthly, if desired, making the process continuous by adding moldsections at the top of the series, separately filling them, and separating moldsections and ingots as before, as and for the purpose stated.

3. The method of forming a continuous steel casting in separable sections partially divided by a cold-shut and rupturing such sections from the casting, which consists in plaoing a continuous series of separate movable mold-sections in succession upon one another, filling each section when placed upon the top of the previous section with a separate charge of fluid metal, and moving each mold-section at the bottom of the series with its contained ingot to rupture the casting at the point weakened by the cold-shut, substantially as herein set forth.

4. The method of forming a continuous steel casting in separable sections partially divided by a cold-shut and rupturing such sections from the casting, which consists in placing-a continuous series of separate movable mold-sections in succession upon one another, filling each section when placed upon the top of the previous section with a separate charge of fluid metal, and moving each mold-section and its contained ingot at the bottom of the series transversely to the ingotcasting to rupture the said ingot, substantially as herein set forth.

5. The method of forming a continuous steel casting in separable sections partially divided by a cold-shut, which consists, first, in filling a vertical mold-section with a separate charge of fluid metal; secondly, applying an annular yielding-packing to the top of said filled section; thirdly, superposing another and bottomless section upon the top of such' filled section; fourthly, pouring a separate charge of metalinto such second section; fifthly, applying separate mold-sections to the top of the series and supplying each of such moldsections with a separate charge of fluid metal when thus applied, and, sixthly, removing the bottom mold-section and the bottom ingot of the series as the new mold-sections are applied to the top, the whole substantially as herein set forth.

6. The process of casting an ingot with distinct portions, which consists in casting one portion, suffering it to set exteriorly, and casting another portion onto the first-cast portion, whereby joints are formed at which the ingot may be broken into sections.

7. The process of casting an ingot with distinct portions, which consists in casting one portion, suffering it to set exteriorly, lowering it, and casting another portion onto the firstcast portion, whereby joints are formed at which the ingot may be subsequently broken into its portions.

8. The process of forming a cast steel or metal ingot, which consists, first, in filling a vertical mold-section with a charge of fluid metal; secondly, supporting on the filled moldsection a second and bottomless mold-section; thirdly, pouring a separate charge of fluid metal in such second mold-section, continuing the process of applying separate mold-sections at the top of the series and supplying them with separate chargesof fluid metal, and removing a mold-section from the bottom of the series at each application of the moldsection to the top, substantially as herein set forth.

9. The process of forming a caststeel or metal ingot and rupturing the ingot into portions, which consists in placing a continuous series of separate movable mold-sections in succession upon one another, filling each section when placed upon the top of the previous section with a separate charge of fluid metal, and moving each mold-section at the bottom of the series with its contained ingot to rupture the casting at the joint of the mold-sections, substantially as herein set forth.

10. The process of forming a cast steel or metal ingot, which consists in placing a continuous series of separate movable mold-see mops? s In testimony whereof I have hereunto set my hand in the presence of two subscribing 10 witnesses.

JAMES B. DAROY BOULTON.

Witnesses:

HENRY V. CONDIOT, CHAS. H. VOORHIS. 

